1

LIST OF FIGURE

Figure 1 Fly Ash…………..………………………………………………………….. 28

Figure 2 Ground Granulated Blast Furnace Slag……………...………………..…….. 30
Figure 3 Course aggregate…………………..…………………………………….….. 31
Figure 4 Fine aggregate……………………………………………...…………..…… 32
Figure 5 Marble Powder ……………………………………………………...……… 33
Figure 6 Sodium silicate…………………………………………………………….... 34
Figure 7 Sodium silicate test report…………………………………………...….…... 35
Figure 8 Sodium hydroxide flakes………………………………………..………...… 36
Figure 9 Geopolymer concrete material………………………………………..…….. 38
Figure 10 Shows flyash content to the compressive strength………………............….. 40
Figure 11 Generalized relations between free alkaline liquid to flyash ratio and
Compressive strength of concrete……………………………………….….. 40
Figure 12 Adjustment of values in sand content percentage…………...……………… 42

2
 LIST OF TABLE

Table 1 Physical properties of fly ash……………………………..………………… 28

Table 2 Chemical composition of fly ash……………………………..…………….. 29
Table 3 Physical properties of GGBFS………………………………….………….. 30
Table 4 Chemical composition of GGBFS………………………………………….. 30
Table 5 Physical properties of course aggregate…………………………………...... 31
Table 6 Physical properties of fine aggregate …………………………………….… 32
Table 7 Physical properties of marble powder……………………………..……….. 33
Table 8 Physical and chemical properties of Sodium silicate……………………..... 35
Table 9 Physical and chemical properties of Sodium hydroxide……………..…….. 37
Table 10 Sodium hydroxide to sodium silicate ratio accordance to comp. strength….. 41
Table 11 Approximate sand contents per cubic meter of concrete for grades up to M35
Grade…………………………………………………………………………42
Table 12 Approximate air content……………………………………………………...42

3
CHAPTER – 1 INTRODUCTION

1.1 GENERAL INTRODUCTION

Expanded clay aggregate is environmentally friendly product is widely used in a very
large range of construction, where its properties of light weight, high strength and durability
suit it ideally for both the stringent structural engineering requirements as well as esthetic and
artistic forms and shapes that provide pleasant places to live and work. Expanded clay
aggregate concrete gives designers greater flexibility in creating solutions to meet the
challenges of dead load, terrain, seismic conditions, construction schedules in today’s
marketplace. Living in harmony with our environment starts with the design process and
includes a holistic perspective. This reference manual shows some of the many ways
Expanded clay aggregate contributes to the overall sustainability of our world.
The expanded clay aggregate industry is a resource efficient industry contributing to a
competitive low carbon economy. The energy is used to produce up to 5 m3 high quality,
efficient and competitive construction material from 1m3 locally available raw material. In
addition, using expanded clay saves energy and reduces CO2 emissions in the construction
and transport sectors. Its low weight means fewer trucks and fewer journeys, thus reducing
the carbon impact of transportation. The thermal insulation properties of expanded clay
materials used in construction, improve the energy performance of the buildings, significantly
contributing towards reducing energy consumption and related CO2 emissions.
The main characteristic of expanded clay is low density combined with high strength.
In addition, the aggregate holds many other important characteristics, and it can be described
as an “all-in-one” product, providing a huge range of properties vital for sustainable
construction. Expanded clay is durable has long lifetime and requires no maintenance
Expanded clay can reduce the weight of concrete by almost 50% without compromising
strength. It is 4-5 times lighter than loose gravel or loose fill crushed stone. It can be used as
loose fill and insulation in road and rail embankments and can sustain dynamic loads from
heavy high-speed trains Expanded clay is 100% recyclable or reusable. There are no
problems with disposing of demolition waste and no use of new materials, new resources or
new energy.

4
 Lightweight aggregates have been used in construction since before the days of the
Roman Empire. The earliest types of lightweight concrete were made by using Grecian and
Italian vesicular volcanic aggregates as lightweight aggregate. Ordinary hydrated burned lime
was used as the cementatious material in the mix. These early lightweight concretes, by
reason of the obviously weak materials, fell short in structural strength and performance of
what we expect and achieve today. They were, however, amazingly durable, and existing
examples of these early lightweight concretes can still be found in various early structures in
the Mediterranean area.
In 1824 Joseph Aspdin, an English bricklayer, conceived the idea of intermixing
pulverized raw limestone and pulverized impure siliceous materials in varying percentages.
He then subjected these mixtures to the high temperatures of coke fires, and pulverized the
resultant clinkers. Aspdin thereby determined the approximate raw compounding required for
maximum strength,
Research for the manufacture of ‘artificial’ aggregates commenced. In Europe in the
early part of the 20th century, development concentrated on foaming blast furnace slags, as
‘iron’ production was basic to the industrial infrastructure. However, it was not until the early
1970s that significant developments in pelletising and expanding blast furnace slags took
place, so that today a slag-based aggregate with a smoother non-vesicular surface ,more
adaptable for structural concrete, is produced.
The first work on expanded clay and slate was undertaken in 1908, it was not until
almost a decade later during World War I (1917-1920) that the product saw any large scale
use, and that in the concrete shipbuilding program undertaken by the United States Fleet
Corporation, an arm of the Federal Government.
This research was therefore dedicated to the development, the manufacture, and the
Engineering properties of the fresh and hardened fly ash and ggbfs based geopolymer
concrete and experimental studies on that.
So finally the ECA is a new development in the world of concrete in where aggregate
is fully or partially is replaced by materials like expanded clay aggregate for the concrete
mix.

5
1.2 DEFINITION

Expanded clay aggregate is a well-established lightweight aggregate suitable for a

wide range of applications. It has proven to be a durable and safe material able to
withstand different climates. “Expanded clay is a well-proven, high quality, efficient
and competitive construction material that can be used anywhere It is sustainable and
packed with properties that improve the economic, social and environmental building
or infrastructure over its whole lifetime” Expanded clay is a high quality, durable
lightweight aggregate, that has been used for over half a century

1.3 IMPORTANCE AND USE OF EXPANDED CLAY AGGREGATE

Expanded clay is produced with the maximum care for environment, climate, and local
communities. Over the last few decades, the reduced both its energy emissions and there is a
commitment to delivering further CO2 emissions. Using waste that cannot be recycled or
reused as substitutes for fossil fuels not only reduces fossil fuel consumption and contributes
to a true circular economy, it also reduces CO2 emissions.
For every cubic metre of natural and abundant clay, up to five cubic metres of expanded clay
is produced. Using expanded clay saves energy and reduces CO 2 emissions in the
construction and transport sectors. Its low weight means fewer trucks and fewer journeys,
thus reducing the carbon impact of transportation. The thermal insulation properties of
expanded clay materials used in construction, improve the energy performance of the
buildings,

The superior properties of Expanded clay aggregate concrete are

 Expanded clay is durable has long lifetime and requires no maintenance

 Non toxic material
 Long working life
 Expanded clay can reduce the weight of concrete by almost 50% without
compromising strength
 Insulating performance of loose fill expanded clay is in thesame range as the best
values of wood.
 Concrete made with expanded clay can be up to 12 times more insulating than
normal concrete: winter and summer comfort is guaranteed Higher compressive
strength
6
1.4 SALIENT FEATURES OF EXPANDED CLAY AGGREGATE
CONCRETE

 Using expanded clay saves energy and reduces CO2 emissions in the construction and
transport sectors.
 The mechanical behavior ECA concrete is higher than nominal concrete mix.
 Durability property of Expanded clay aggregate concrete is higher than the nominal
concrete mix.
 Expanded clay aggregate concrete is eco-friendly.
 Expanded clay aggregate strongly resists against alkaline and acidic substances and
pH of nearly 7 makes it neutral in chemical post reaction with concrete.

1.5 REPORT ARRANGEMENT

The report arrangement is as per under given

Chapter-1 introduction about the Expanded clay aggregate concrete and describes it’s
importance & uses.

Chapter-2 A detailed literature review of the past research paper to find alternative
aggregate to manufacture concrete and use it to manufacture the Expanded clay
aggregate(ECA) concrete . This chapter also provides past experimental study results and
conclusion from literature review of ECA technology.

Chapter-3 Describes the aim of the present research work & scope of work and also
explains necessity of Expanded clay aggregate concrete.

Chapter-4 In these chapter full details of total project work with work plan and
methodology, details starting from introduction to the end of the results in which cover entire
research work for both phase.

Chapter-5 This chapter give a partial details of the all material used for this research
work and its some physical & chemical properties.

7
 Chapter-6 The illustrative example for nominal mix design of Expanded clay
aggregate (ECA)concrete is given in details with standard calculations and mixing proportion
of (ECA) Expanded clay aggregate (% wise replacement table)

Chapter-7 This chapter deals with the experimental program carried out to develop
the different mixture proportions, the mixing & casting process, and curing regime of
Expanded clay aggregate concrete. The tests performed to study the strength properties of
the hardened concrete at 3day, 7day & 28 day.

Chapter-8 To study of the tested specimens and discusses the test results and
compare to the normal results. Also states the summary and the conclusions of this study. The
report ends with a reference list…

Note: Chapter-7 and Chapter-8 are not present in this report of DP-1, this Chapter is given in
final report of research work after completing all work of experimental studies on Expanded
clay aggregate concrete.

8
CHAPTER – 2 LITERATURE REVIEW

2.1 GENERAL

In this chapter a background over the environmental impacts from the manufacturing
process of Expanded clay aggregate and the main aggregate alternatives will be represented
and also research has been conducted into the previous investigation Expanded clay
aggregate and its mechanical properties resulting from mix design and parameters which may
have influences on Expanded clay aggregate properties. The available published literature on
Expanded clay technology is also briefly review and summarize here.

2.2 REVIEW OF RESEARCH PAPER…

2.2.1 RESEARCH PAPER * 1

PAPER TITLE: STUDY OF REINFORCEMENT CORROSION IN EXPANDED CLAY

CONCRETE

AUTHOR: A.V. Uglyanitsa, N.V. Gilyazidinova, A.A. Zhikharev, A.A. Kargin

PUBLISHED IN JOURNAL AND YEAR: HBRC, HBRC Journal (2015) 11, 307–310,
5 August 2014

OBJECTIVES OF STUDY:

Expanded clay concrete differs from heavy-weight concrete not only by the composition and
performance properties, but also by modes of chemical interactions between the components.
So, not the primary problem of reinforcement corrosion in heavy-weight concrete under the
normal conditions and the correct protective layer, becomes in the major problem in
expanded clay concrete. The issue of reinforcement corrosion in expanded clay concrete is
considered in this article. The studies on the effect of different compositions on the
corrosiveness were conducted. Researchers have proposed various options for expanded clay
concrete reinforcement protection from the environmental impact, including those through a
variety of chemically active additives. According to the data obtained by experimenting, the
diagrams of corroded area size dependence on various factors were presented. The results of
the studies conducted are the recommended design and technological measures.
For the reinforcement protection against corrosion in various fine aggregate-based (natural
sand, ash and dry hydro removal) light-weight expanded clay concrete. Thus, the minimum

9
concrete protective cover for main and distribution reinforcement of external walls must be at
least 25 mm. It is necessary to inject additives – reinforcement corrosion inhibitors (sodium
nitrite, sodium tetra borate) to the concrete composition. The consumption of cement, and
hence, the cement paste content of concrete mixture must be not lower than 220 kg/m3, and
under the application of the active dry fly ash removal _200 kg/m3

OUTCOME OF STUDY:

 Expanded clay concrete on the basis of natural compact sand with the portland
cement consumption rate less than 250 kg/m3 does not provide the reinforcement
protection against corrosion. It develops not only when the protective layer is 15 and
20 mm, but also at 25 mm. Marks and spots of corrosion are visually detected when
the samples are stored under atmospheric conditions for 240 days. The increase in
cement content up to 350 kg/m3 reduces, but does not stop the reinforcement
corrosion.
 The substitution of natural sand in the composition of expanded clay concrete by ash
fly of hydraulic removal with the cement consumption rate of up to 250 kg/m3
contributes to the accelerated development of corrosion processes both during the
accelerated technique-based tests, and in the natural storage samples. Probably,
along with the increase in porosity and moisture content of expanded clay concrete,
the increase in this fine aggregate dispersion results in the reduction of the cement
paste content and activity.
 Expanded clay concrete on the fine aggregate of hydraulically active fly ash at a low
rate of portland cement consumption of 180–200 kg/m3 does not protect the rebar
from corrosion when the protective layer is 25 mm. With the increase in cement
consumption up to 250 kg/m3 the intensity of development of corrosion processes is
reduced, but does not stop.
 The introduction of steel corrosion inhibitor on the basis of natural sand and ashes of
hydraulic removal of thermal power stations (sodium nitrate or sodium nitrite
+sodium tetra borate with the amount of respectively 1.8 and 0.3% of cement
consumption) to expanded clay concrete on the fine aggregate eliminates the
reinforcement corrosion with the protective layer thickness of 25 mm. In natural
conditions of sample storage for 240 days the development of corrosion process has
not been detected.
 The conducted studies result in the recommended design and technological
measures to protect the reinforcement against corrosion in lightweight expanded
clay concrete on various fine aggregates – natural sand, ashes of dry and hydraulic
removal of thermal power stations; – the protective concrete layer for the principal
reinforcing and distribution bars of the outer wall should not be less than 25 mm; –
the reinforcement corrosion inhibitor should be added to the cement composition; –
the cement consumption, and hence, the cement paste content in concrete mixture
must be not lower than 220 kg/m3, when applying active fly ash of dry removal-200
kg/m3.

10
2.2.2 RESEARCH PAPER * 2

PAPER TITLE: COMPARISON OF MATERIAL PROPERTIES OF LIGHTWEIGHT

CONCRETE WITH RECYCLED POLYETHYLENE AND EXPANDED CLAY
AGGREGATES

AUTHOR: DEIVIDAS RUMŠYSA*, DARIUS BAČINSKASA, EDMUNDAS

SPUDULISA,B, ADAS MEŠKĖNASA,C
PUBLISHED IN JOURNAL AND YEAR: MBMST 2016, 172 ( 2017 ) 937 – 944

OBJECTIVE OF STUDY:
The article discusses the possibility of using high and low density polyethylene waste as
aggregate in lightweight concrete with high strength cement mortar. Research is dedicated to
experimental investigation and comparison of material properties of concrete made of
polyethylene waste and expanded clay aggregates. Hydration kinetics studies of concrete
specimens with different aggregates are performed using measurements of ultrasonic pulse
velocity. For the experimental investigation high and low density polyethylene plastic waste
aggregates with low water absorption and hydrophobic surface were used. It is stated that
concrete with low water absorption plastic waste aggregates after 7 days of curing showed
significant decrease in strength growth rate. The specimens had a density of 1950 – 2050
kg/m3 with a compressive strength of at least 40 MPa. Using pre-wetted expanded clay
aggregate with similar mix composition, concrete density was 1900 kg/m3 with a
compressive strength up to 70.2 MPa. Although having similar mechanical properties as the
waste plastic aggregate, pre-wetted expanded clay allows better cement hydration process,
resulting in lower water absorption of lightweight concrete.

OUTCOME OF STUDY:

 It was found that UPV methodology allows to observe cement hydration process
peculiarities of concrete with different water absorption aggregates. After 7 days of
curing concrete with plastic waste aggregates (which have a very low water
absorption), a significant decrease in growth of strength properties is observed in
comparison to concrete with pre-wetted expanded clay aggregate.

11
 Concrete composition having a density of 1950 to 2050 kg/m3 with plastic waste
aggregates HDPE and LPDE has 28 days compressive strength higher than 40 MPa.
Using pre-wetted expanded clay aggregate with same cement
 mortar resulted in the density of 1900 kg/m3 with a compressive strength up to 70.2
MPa.
 Although having similar mechanical properties as the waste plastic aggregate, higher
porosity pre-wetted expanded clay aggregate creates optimal conditions for cement
hydration, which results two times lower water absorption.
 Additional mechanical treatment of HDPE beads did not influence compressive
strength and water absorption of concrete.
 It was found that the application of silica fume micro-fillers in concrete mixture at
the same W/S ratio gives higher compressive strength and lower water absorption in
comparison to ground quartz micro-filler.

12
2.2.3 RESEARCH PAPER * 3

PAPER TITLE: EXPERIMENTAL INVESTIGATION ON MECHANICAL

PROPERTIES OF LIGHT WEIGHT CONCRETE USING LECA

AUTHOR: T. SONIA1, R. SUBASHINI1

PUBLISHED IN JOURNAL AND YEAR: ISSN (Online): 2319-7064, 11, November 2016

OBJECTIVE OF STUDY:
This study examined the structural behaviour of Lightweight concrete (LWAC) using
lightweight aggregates (Light expanded clay aggregates LECA) and normal weight
aggregates, aims to investigate on concrete mix M25 by the effect of partially and fully
replacement of the coarse aggregate by Leca with various percentage such as 20%, 40%,
60%, 80% and 100% and fly ash percentage such as 15%, 20%, 25% used as partial
replacement for cement in concrete. Analysis of this concrete was done in fresh state as well
in hardened state to evaluate physical and mechanical properties of concrete. This paper
concentrated on performance parameters such as compressive strength, splitting tensile
strength of the light weight concrete using LECA. The Lightweight concrete density varies
from 40% - 100% replacement of LECA such as 1996kg/m3-1597kg/m3. It reduces the
weight of concrete and cost of concrete by reducing the aggregate cost and produces
economical system. In strength performance of 15% replacement of fly ash content with 40%
replacement of coarse aggregates concrete for better results to ensure its optimal proportions.

OUTCOME OF STUDY:
 The density of concrete is found to decrease with the increase in percentage
replacement of normal aggregate by Light Expanded Clay Aggregate.
 Compressive Strength and split tensile strength of concrete is found to decrease from
34.60 to 21.77 MPa and 3.20 to 1.5 MPa respectively with increase
 in Leca content from 0% to 100%
 The Leca concretes when replaced with 40% and 60% of coarse aggregates shown
better results, when compared to conventional concrete.

13
 The experimental work carried out to optimize the fly ash content in cement and from
the results obtained, I recommended the replacement of cement by 15% fly ash gives
better results.

14
2.2.4 RESEARCH PAPER * 4

PAPER TITLE: A COMPARISON OF STRENGTH AND ELASTIC PROPERTIES

BETWEEN CONVENTIONAL AND LIGHTWEIGHT STRUCTURAL CONCRETES
DESIGNED WITH EXPANDED CLAY AGGREGATES

AUTHOR: MURAT EMRE DILLI, HAKAN NURI ATAHAN , CENGIZ S_ENGÜL

PUBLISHED IN JOURNAL AND YEAR: CONSTRUCTION AND BUILDING
MATERIALS 101 (2015) 260–267

OBJECTIVE OF STUDY:
Properties such as compressive strength, modulus of elasticity (MOE), Poisson’s ratio and the
ductility of lightweight aggregate concrete (LWAC) mixtures were investigated, and the
results obtained were compared with conventional concrete (CC) mixtures with similar
design characteristics. For this purpose, LWAC mixtures were casted using lightweight
expanded clay (EC) aggregates with different unit weight properties. Dry unit weights of
LWAC mixtures changed approximately between 1640 kg/m3 and 2050 kg/m3. To express
the effect of matrix strength on the determined properties, concrete mixtures with different
matrix strengths were designed by keeping the total aggregate volume constant. For this
purpose, the water to cementitious material ratio and the amount of cementitious materials
were changed. Results have shown that, depending on the unit weight of concrete, the
compressive strength of LWAC mixtures varied between 20 MPa and 70 MPa. Compared
with CC mixtures, the elastic properties and ductility of LWAC mixtures changed
significantly. Within the same compressive strength range, LWAC mixtures showed
remarkable reduction in MOE and more brittle behavior compared with CC mixtures.
Poisson’s ratios of the LWAC and CC mixtures, on the other hand, produced similar values.
A new model for predicting the MOE of such concretes is also suggested.

OUTCOME OF STUDY:
 Depending on the water to cementitious material ratio, the average 120-day
compressive strengths of concretes varied between 24 MPa and 31 MPa for LWAC-1,
52 MPa and 68 MPa for LWAC-2 and, 61 MPa and 75 MPa for conventional concrete

15
 mixtures.
 At the end of 28-days of curing, compared with CC mixtures, LWAC-2 mixtures
presented higher compressive strength values for all w/cm ratios. This result can be
attributed to the satisfactory strength properties of EC2 coarse aggregates and the
better bond characteristics between the EC2 aggregates and the cementitious
matrix.
 Very high water absorption capacities of EC aggregates provided better internal
curing, especially for the LWAC-2 mixtures with a lower w/cm ratio. It is likely that,
for a given water to cementitious material ratio, the matrix strength of LWAC-2
mixtures was improved as compared with CC mixtures.
 For both LWAC-2 and CC mixtures, regardless of the w/cm ratio, the compressive
strength increases over time. However, as a result of a longer hydration period, as
the matrix strength
 Increase the aggregate characteristics begin to play an important role in determining
the maximum concrete strength that can be reached.
 In general, as the compressive strength increases, the MOE of concretes increase. It
is very obvious that both the strength development and the aggregate type have
very significant effect on the MOE of concretes.
 The prediction of MOE of concretes is not satisfactory when only considering its
compressive strength. For obtaining more precise prediction models, factors such as
aggregate type and the density of hardened concrete must be adapted into the
prediction models.
 Based on the test result obtained in this work, new prediction models were
developed.

16
2.2.5 RESEARCH PAPER * 5

PAPER TITLE: EXAMINATION OF EFFECTIVE PARAMETERS FOR THE

PRODUCTION OF EXPANDED CLAY AGGREGATE

AUTHOR: A. OZGUVEN A,, L. GUNDUZ

PUBLISHED IN JOURNAL AND YEAR: CEMENT & CONCRETE COMPOSITES 34
(2012) 781–787. 28 FEBRUARY 2012

OBJECTIVE OF STUDY:
It is important to know which parameters are effective for the manufacture of expanded clay
aggregate and to determine how effective these parameters are on expansion. In this study,
expansion tests were conducted by using samples from three separate fields to determine how
different parameters influence manufacturing. Clay grain size, pellet size, temperature in the
furnace and firing time were selected in the expansion tests as parameters. Their effect on
production was evidenced separately. It was found that decreasing the clay size has a positive
effect on expansion while a decrease in pellet size has a negative effect on it. Also,
temperature in the furnace and the time period during which the clay remains in thefurnace
are critical values for the resultant aggregate quality. The conditions for optimum
manufacturing were explained in detail.

OUTCOME OF STUDY:
 Decreasing the clay grain size, which is one of the manufacturing parameters, results
in an increase in expansion. To produce aggregate that meets the requirements of its
intended application, while reducing manufacturing cost, clay size should be
optimized.
 As pellet size increases, expansion also increases. If a lower density is required in
manufacturing aggregates in a desired size, a pellet size close to the maximum point
within that pellet size range may be chosen.
 The temperature inside the furnace is the most significant parameter, which must be
ensured. Expansion increases as temperature increases up to near the melting point,
which varies according to clay type. Thus, an optimum temperature should be
specified according to the type of clay.
 To reduce unit manufacturing cost, the lowest possible temperature should be
employed in manufacturing to achieve the desired aggregate density.

17
2.2.6 RESEARCH PAPER * 6

PAPER TITLE: IN-SITU THERMO-MECHANICAL TESTING OF FLY ASH

GEOPOLYMER CONCRETES MADE WITH QUARTZ AND EXPANDED CLAY
AGGREGATES

AUTHOR: WILLIAM D.A. RICKARD , GREGOR J.G. GLUTH ,, KLAUS PISTOL

PUBLISHED IN JOURNAL AND YEAR: ELSEVIER, 80 (2016) 33–43, 16 November
2015
OBJECTIVE OF STUDY:
The mechanical and microstructural properties of geopolymer concretes were
assessed before, during and after high temperature exposure in order to better understand the
engineering properties of the material. Fly ash based geopolymer concretes with either quartz
aggregate or expanded clay aggregate were exposed to various temperatures up to 750 °C
using a thermo-mechanical testing apparatus. Microstructural investigations were also
undertaken to better understand the measured changes in the mechanical properties. It was
found that dehydration of capillary water caused cracking and strength losses at temperatures
≤300 °C, an effect that was more severe in the quartz aggregate geopolymer due to its lower
permeability. At higher temperatures (T ≥ 500 °C) sintering promoted strength increases
which enabled both concrete types to yield significant strength advantages over conventional
materials. Stress–mechanical strain curves, which form the basis of the fire design of concrete
structures, are reported.

OUTCOME OF STUDY:

A series of engineering tests have been applied to two types of geopolymer concrete in order
to assess their performance at elevated temperatures. The analysis of concretes represents a
progression from small scale paste tests towards full scale tests and commercialization of the
material. It was determined that dehydration at T ≤ 300 °C caused substantial damage in the
geopolymer concretes, an effect that was more severe in the quartz aggregate geopolymer due
to its lower permeability. At high temperatures (T ≥ 500 °C) the geopolymer concretes
exhibited significant strength advantages over conventional materials.

18
2.2.7 RESEARCH PAPER * 7

PAPER TITLE: DEVELOPMENT OF INNOVATIVE STRUCTURAL LIGHT WEIGHT

CONCRETE BY USING EXPANDED CLAY AGGREGATES

AUTHOR: PRAMOD B. SALGAR, P. S. PATIL

PUBLISHED IN JOURNAL AND YEAR: MANTECH VOLUME 2 ISSUE 1,2017

OBJECTIVE OF STUDY:
Lightweight concrete can be produced by replacing the normal aggregate with lightweight
aggregate, either partially or fully, depending upon the requirements of density and strength.
The present study covers the use of Expanded Clay Aggregate (LECA) as lightweight
aggregate in concretes containing micro silica as a supplementary cementations material. The
main aim of this project is to develop the Lightweight concrete for structural use. The
different mixes were designed by using the efficiency of micro silica with the different
percentages of light weight aggregate LECA and Sintagg. The resulting concretes were seen
to have densities varying from 900 to 1860 kg/m3, with the corresponding compressive
strengths varying from 5 to 35 MPa which leads in reduction of dead load, faster building
rates and lower haulage and handling costs to pull off economy.

OUTCOME OF STUDY:
1. Light weight concrete is a very good material because it can substantially reduce the dead
weight up to 40%-53% while maintaining the other non-structural requirements.
2. The compressive strength for 100% Expanded clay aggregate concrete was observed as
5.74 N/mm2. As a percentage of natural aggregates were increased, the compressive strength
was increased up to 12N/mm2.
3. Under uniaxial compression loading Failure cracks generated were approximately parallel
to the direction of loads with some cracks angular to applied load. In failure of concrete it is
observed, aggregates were fails first.
4. The compressive strength for Sintagg aggregate concrete was observed as 35.31 N/mm2
(which is more than minimum strength for structural use by IS code i.e. 17MPa) Hence
Sintagg aggregate light weight concrete should be used as structural concrete.

19
20
2.2.8 RESEARCH PAPER * 8

PAPER TITLE: STUDY ON FLY ASH AND GGBS BASED GEOPOLYMER

CONCRETE UNDER AMBIENT CURING

AUTHOR: ROHIT ZENDE, MAMATHA. A.

PUBLISHED IN JOURNAL AND YEAR: HINDAWI, VOLUME 2015, ARTICLE ID
849274
OBJECTIVE OF STUDY:

Light expanded
clay aggregate (LECA), generally, includes tiny, lightweight,bloated particles of burnt clay.
The hundreds and thousands of tiny, air-filled depressions successfully empower LECA with
its sterling strength and thermal insulation qualities.The average water absorption of LECA
total (0–25 mm) is thought to associate with 18 percent of volume in saturated status amid the
time of 3 days. The ordinary Portland cement (OPC) is partially substituted by the fly ash,
fine aggregate interchanged by bottom ash, and coarse aggregate supplanted by light
expanded clay aggregate (LECA) by weights of 5%, 10%, 15%, 20%, 25%, 30%, and 35%,
separately. The compressive strength, split tensile strength, and flexural strength are
successfully assessed by means of determined input values in concurrent investigation.

OUTCOME OF STUDY:

The paper attains the highest possible strength for LECA concrete while noting the advanced
technology in producing light weight concrete. The results show that 5% replacement of
cement with fly ash, fine aggregate with bottom ash, and coarse aggregate with light
expanded clay aggregate (LECA) was found to be good performance in compressive strength,
split tensile strength, and flexural strength of beam in 56 days when compared with 28 days
strength. At the same time 28 days strength also approximately equals normal conventional
concrete; that is, 0% replacement and dry weight of specimen have been reduced. In future,
soft computing techniques will lead with core areas us to attain better performance in short
interval of time as the time is the major factor involved in this research work.

21
2.2.9 RESEARCH PAPER * 9

PAPER TITLE: BEHAVIOUR OF LIGHTWEIGHT EXPANDED CLAY AGGREGATE

CONCRETE EXPOSED TO HIGH TEMPERATURES

AUTHOR: LENKA BODNÁROVÁ, RUDOLF HELA, MICHALA HUBERTOVÁ, IVETA

NOVÁKOVÁ
PUBLISHED IN JOURNAL AND YEAR: INTERNATIONAL SCIENCE INDEX, CIVIL
AND ENVIRONMENTAL ENGINEERING VOL:8, NO:12, 2014

OBJECTIVE OF STUDY:

This paper is concerning the issues of behaviour of lightweight expanded clay aggregates
concrete exposed to high temperature. Lightweight aggregates from expanded clay are
produced by firing of row material up to temperature 1050°C.Lightweight aggregates have
suitable properties in terms of volume stability, when exposed to temperatures up to 1050°C,
which could indicate their suitability for construction applications with higher risk of fire.
The test samples were exposed to heat by using the standard temperature-time curve ISO 834.
Negative changes in resulting mechanical properties, such as compressive strength, tensile
strength, and flexural strength were evaluated. Also visual evaluation of the specimen was
performed. On specimen exposed to excessive heat, an explosive spalling could be observed,
due to evaporation of considerable amount of unbounded water from the inner structure of
the concrete.

OUTCOME OF STUDY:

 The compactness and bearing capacity of light weight concrete with higher moisture
content was disrupt at temperature 700°C which is equal to 20 minutes of fire.
 If the moisture content is lower than 10% of weight the fire resistance of lightweight
concrete LC [7] is not influenced.
 The fire resistance of the lightweight concrete is rapidly decreasing with decreasing
moisture content. This assertion is valued for moisture content from 10 to 20%.In
further studies could be defined exact limit for moisture content.

22
 The results should be taken in account when using lightweight concrete in
environment or construction with requirements of fire resistance (tunnel lining,
industrial spaces with high humidity etc.).
 The type of technological process of preparing lightweight concrete influences the
fire resistance of the concrete in first weeks or months of curing. In this period the
fire resistance could not be sufficient.

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2.3 SUMMARY OF LITERATURE REVIEW AND PROBLEM
DEFINITION…

 From above research paper it can be concluded that Expanded clay aggregate is a
better alternative for lightweight concrete.
 The expanded clay aggregate is a better alternative for higher durable concrete.
 Based upon above literature review it could be concluded that all researchers have put
their efforts to show the effect of expanded clay aggregate on Expanded clay
aggregate concrete. However it should be noted that with the variation in the
parameters such as water cement ratio, curing temperature, curing time makes the
variation in the strength.. However well water cured cubes shows higher compressive
strength
 The optimum replacement level of ECA in ECA concrete will be carried out. Water
absorption property of ECA is higher than the nominal aggregate. hence, the
Expanded clay aggregate will be soaked in water before 48 hours of it’s use in
concrete.
 To not face any water absorption problem on fresh concrete it is advisable to soaked
aggregate in water before 48 hours of it use. in 48 hours it will absorb maximum
capacity of water on it. And it will not take water of fresh concrete on it.
 From the literature also conclude that when the ratio of water cement decreased then
the strength of concrete also increases.
 Also notice that the ECA concrete gives lightweight concrete without compromising
compressive strength.
 Expanded clay aggregate concrete with properties such as abundant raw resource,
lower CO2 emission, less energy consumption, low unit cost, high strength, resistant
to corrosive environment, higher durability, higher fire resistivity These properties
make expanded clay aggregate concrete to find great application in civil engineering.

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CHAPTER – 3 AIM OF THE RESERCH & SCOPE
OF WORK

3.1 NECESSITY OF EXPANDED CLAY AGGREGATE CONCRETE

Civil construction is a fastest growing industry on world . As per the present world
statistics, every year around 51.7 billion metric tons of aggregate is required. This quantity
will be increased in next 10 years in large numbers . Since the fine aggregate is the main
source material for the concrete More over while producing one ton of concrete,
approximately large amount of carbon dioxide will be emitted to the atmosphere, which is a
major threat for the environment. In addition to the above huge quantity of energy is also
required for the mining of fine aggregate. Hence it is most essential to find an alternative of
it.
Expanded clay aggregate is a well-established lightweight aggregate suitable for a wide
range of applications. It has proven to be a durable and safe material able to withstand
different climates all over the world
“Expanded clay is a well-proven, high quality, efficient and competitive
construction material that can be used anywhere. It is sustainable and packed with properties
that improve the economic, social and environmental performance of a building or
infrastructure over its whole lifetime” Expanded clay is a high quality, durable lightweight
aggregate, that has been used for over half a century. The main characteristic of expanded
clay is low density combined with high strength. In addition, the aggregate holds many other
important characteristics, and it can be described as an “all-in-one” product, providing a huge
range of properties vital for sustainable construction.

3.2 OBJECTIVE OF RESERCH

The objective of the present research is to study the effect of Expanded clay aggregate as a
replacement of fine aggregate on concrete and inspecting the mechanical properties of
hardened concrete at 3day, 7 day & 28 day. The casted cube will be cured on a curing tank.
Advantages of ECA concrete include durable has long lifetime and requires no maintenance
Expanded clay can reduce the weight of concrete by almost 50% without compromising
strength, It can be used as loose fill and insulation in road and rail embankments and can
25
sustain dynamic loads from heavy high-speed trains It is classified as a fully non-combustible
material. It has no reaction to fire, does not emit gases or smoke and retains its mechanical
resistance and all other thermal and physical characteristics. It is an excellent protection
against fire, good mechanical and durability properties.
In this investigation we are attempting to make Expanded clay aggregate concrete
more sustainable by partially replacing the fine aggregate with expanded clay aggregate.
This study is mainly aimed to achieve ECA based ECA concrete which is higher
durable, higher compressive strength more sustainable than nominal concrete.

3.3 APPLICATIONS OF ECA CONCRETE

 Expanded clay aggregate is used extensively in new buildings, the restoration of

historicalbuildings and renovation projects. Expanded clay can be used in all
elements of construction from foundations to rooftop. It is primarily used in
internal and external masonry walls.
 The unique material properties provide solutions for stabilizing and restoring
foundations of historical buildings while preserving the original structures.
 Expanded clay is used in civil engineering projects including road and railway
embankments. The material’s lightweight characteristics and durability provides
engineers with proven solutions for challenging ground conditions. Other uses
include bridge abutments, retaining walls, tunnel and pipe-line coverings.
 Expanded clay is used in building foundations including where there are unstable
ground conditions. This is particularly important in the reclamation of
urban“brown-field” sites. It is also used in noise barriers and in engineering
works built to mitigate the environmental impact of infrastructure projects.

3.4 SCOPE OF STUDY

This project report is investigating the strength properties of Expanded clay aggregate
based higher durable structural concrete and tests mixtures with various percentages of
expanded clay aggregate as fine aggregates replacement in order to find their strength
properties and will also be involved with the durability aspects of expanded clay aggregate
concrete.
This research is only about expanded clay aggregate concrete and. This study focused
on applicability of proposed methods to product concrete with adequate compressive strength
that can be used as structural components.
26
 Lack of adequate standards for ECA existence with different compositions may lead
to different results and conclusions. In fact, source material with different density
composition may cause different properties in which is a problem in comparing the results
from the researches from all around the world. Even small percentage of difference in ECA
composition may produce large differences in results of one study to another one.

27
 CHAPTER – 4 METHODOLOGIES

4.1 CHART OF WORK PLAN

DATA COLLECTION

STUDY LITERATURE REVIEW

PROBLEM IDENTIFICATION

SELECTING , PURCHASING,COLLECTING OF DP-1

MATERIAL

MATERIAL PHYSICAL,
MECHANICAL PROPERTIES
TESTING

PREPARE TRIAL MIX DESIGN

QUANTIFY MIXING PROPORTION OF

ECA (% WISE REPLACING MATERIAL)

CASTING OF TRIAL MIX SPECIMENS (ECA)

MS
ECA MIX DESIGN PREPARATION

MIXING, CASTING & CURING OF SPECIMENS

TESTING OF SPECIMEN

ANALYSIS OF THE TEST RESULTS DP-2

28

CONCLUSION
4.2 DESCRIPTION OF EXPIREMENT PROCEDURE

 First of all i have collect information and data about expanded clay aggregate
concrete.

 I have collect data from research paper, internet, reference book and also from guide.

 I have refers many research paper and past experimental study on expanded clay
aggregate based concrete.
 For preparing mix design i have assume the ratio ECA on concrete. take it percentage
wise replacement as fine aggregate in concrete.

 Then after it i have prepare trial mix design for normal ECA concrete and test on it,
and also decide quantity of replacement with different proportion of ECA.
 Then after it casting Expanded clay aggregate concrete block with ECA and also
without this admixture and compare their strength properties and know what
difference happened in strength using by different % of ECA

 After comparing all reading of strength with normal strength. We decide how much
percentage of Expanded clay aggregate are able to increase strength and which types
of strength improve like compression, tensile or flexural strength etc.

 Throughout this project a specific method was used to improve upon previous work.


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CHAPTER – 5 MATERIAL PROPERTIES

5.1 INGREDIANTS USED FOR THIS EXPERIMENT

This study is based on Expanded clay aggregate concrete , so mostly discussion about
ECA and material used for that and other admixtures for partial replacing. All material used
for this research is listed below.

1. Coarse aggregate
2. Fine aggregate
3. Water
4. Cement
5. Expanded clay aggregate(fine)

Shown details about material with its some properties

5.1.1COARSE AGGREGATE

The aggregate consists of natural occurring crushed, uncrushed stones, gravel and
sand. It should be strong, clear, hard, durable, dense, and free from adherent coating and free
from disintegrate pieces, alkali, and other deleterious substances as far as possible. Flaky and
elongation pieces should be avoided. In this investigation the locally available aggregates
from crusher 20mm sieve passing and 10 mm sieve retained is used. It should be angular in
shape.
Properties Results
Shape Angular
Specific gravity 2.7
Fineness modules 7.54
Water absorption 0.5 %
Bulk density 1366 kg/m3
Maximum size 10 mm

TABLE 1: PHYSICAL PROPERTIES OF COURSE AGGREGATE

30
 FIGURE 1: COARSE AGGREGATE

5.1.2 FINE AGGREGATE

In this investigation natural river sand is used as fine aggregate. Sand was obtained
from local sources. Fine aggregate which is passing through is 4.75mm sieve and retained on
is 150 micron sieve is considered for the experimental program.

Properties Results
Type Uncrushed (natural)
Specific gravity 2.42
Fineness modulus 2.76
Water absorption 0.5 %
Bulk density 1668 kg/m3
Maximum size 4.75mm

TABLE 2: PHYSICAL PROPERTIES OF FINE AGGREGATE

31
 FIGURE 2: FINE AGGREGATE

5.1.3 WATER

Potable water was used in this investigation for workability purpose only, to wet the surface
of aggregates to develop adhesion because the dry pastes adheres quickly and satisfactory to
the wet surface of the aggregates than to a dry surface, to prepare a plastic mixture of the
various ingredients and to impart workability to concrete to facilitate placing in the desired
position.

FIGURE-3.WATER
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5.1.4. CEMENT

A cement is a binder, a substance used for construction that sets, hardens and

adheres to other materials, binding them together. Cement is seldom used solely, but is used
to bind sand and gravel (aggregate) together. Cement is used with fine aggregate to
produce mortar for masonry, or with sand and gravel aggregates to produce concrete.Cements
used in construction are usually inorganic, often lime or calcium silicate based, and can be
characterized as being either hydraulic or non-hydraulic, depending upon the ability of the
cement to set in the presence of water

FIGURE-4.CEMENT

Properties Results
Type OPC(53grade)
Specific gravity 3.15
Bulk density 1660 kg/m3
Particle size 50 micron
TABLE-4 CEMENT PROPERTIES

5.1.5. EXPANDED CLAY AGGREGATE

Expanded clay aggregate (ECA) or expanded clay (exclay) is a light weight aggregate made
by heating clay to around 1,200 °C (2,190 °F) in a rotary kiln. The yielding gases expand the
clay by thousands of small bubbles forming during heating producing a honeycomb structure.
LECA has an approximately round or potato shape due to circular movement in the kiln, and

33
Is available in different sizes and densities. ECA is used to make lightweight concrete
products and other uses. Common uses are in concrete blocks, concrete slabs, geotechnical
fillings, lightweight concrete, water treatment

FIGURE-5.EXPANDED CLAY FINE AGGREGATE

CHAPTER – 6 NOMINAL MIX DESIGN FOR

GEOPOLYMER CONCRETE
From the literature study I have noted that unlike conventional fine aggregates the
expanded clay aggregate are a new class of construction materials and therefore no standard
mix design approaches are yet available for ECA concrete .
So that here the conventional method used in the making of normal concrete is
adopted to prepare ECA concrete. Nominal mix design of ECA concrete is calculated based
on * IS CODE 10262-(2009) * and also reference from past Research paper.

34
  ILLUSTRATIVE EXAMPLE FOR GEOPOLYMER CONCRETE
MIX DESIGN

An example illustrating the mix design for a geopolymer concrete of M 25 grade is

given below:

6.1 DESIGN STIPULATIONS

1) Grade of designation = M-20

2) Maximum size of aggregate = 20mm
3) Maximum cement content = 300 Kg/m3
4) Maximum w/c ratio = 0.55
5) Workability in terms of slump = 100 mm
6) Degree of exposure condition = Mild
7) Degree of supervison = good
8) Maximum cement content = 450 Kg/m3

6.2 TEST DATA FOR MATERIALS

1) Cement used = OPC 53 grade
2) Specific gravity of cement = 3.15
3) Specific gravity of natural coarse aggregate = 2.04
4) Specific gravity of fine aggregate = 2.62
5) Specific gravity of ECLA = 1.0
6) Fine aggregate conforming zone-II
7) Water absorption of natural coarse aggregate = 0.5%
8) Water absorption of natural coarse aggregate = 1.0%

6.3 TARGET STRENGTH FOR MIX PROPORTION

f’ck = fck + 1.65 s
where
f’ck = target average compressive strength at 28 days,
fck = characteristic compressive strength at 28 days,
s = standard deviation
So here = 20 + 1.65 *4
= 26.6

35
6.4 SELECTION OF WATER CEMENT RATIO
From IS 456 Table-5 Minimum w/c ratio is 0.55
Hence we adopt w/c ratio is 0.5

6.5 SELECTION OF WATER CONTENT

From table-2 maximum water content =186 liter (for 25 to 50 mm slump range)
For 100 m estimated slump water content is =186+0.06*186 = 197 litre

6.6 CALCULATION OF CEMENT CONTENT

w/c =0.5
197/c =0.5
C= 394 kg/m3 > 300 kg/m3
Hence ok

6.7 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT
1) Zone of fine aggregate = Zone-II
2) Change in w/c ratio with referance to 0.5 = 0
3) Maximum size of coarse aggregate = 20 mm
4) Volume of coarse aggregate = 0.62
5) Volume of fine aggregate = 0.38

6.7 MIX CALCULATION

1) Volume of concrete = 1 m3
2) Volume of cement = 0.125 m3
3) Volume of water = 0.197 m3
4) Volume of all aggregate = 0.678
5) Proportion of 20 and 10 mm is 60% - 40%
6) Mass of coarse aggregate = 857 Kg/m3
7) Mass of fine aggregate = 675 Kg/m3

36
6.8 TRIAL MIX TABLE

0% 10% 20% 30% 40%

Water content 197.16 197.16 197.16 197.16 197.16
Cement content 395 395 395 395 395
Natural coarse 857.00 787.50 685.60 599.90 514.20
aggregate
Natural fine aggregate 675 675 675 675 675
Expanded clay 0.00 23.045 46.09 69.135 92.18
lightweight aggregate

6.9 NOS. OF SPECIMEN WILL BE CASTED

Elements Nos. for one Nos. for Size of specimen Testing at Type of test
percentage five in mm nos of days to be
percentag conducted
e
Cube 3 Nos. 15 Nos. 150 * 150* 150 7 days Compressive
strength
3 Nos. 15 Nos. 150 * 150* 150 28 days
3 Nos. 15 Nos. 150 * 150* 150 56 days Durability
(Acid +
3 Nos. 15 Nos. 150 * 150* 150 56 days
Alcalinity)
3 Nos. 15 Nos. 150 * 150* 150 90 days
3 Nos. 15 Nos. 150 * 150* 150 90 days
Beam 3 Nos. 15 Nos. 100 *100 * 500 28 days Flexural
strength
3 Nos. 15 Nos. 100 *100 * 500 56 days Drability test
3 Nos. 15 Nos. 100 *100 * 500 56 days
Cylinder 3 Nos. 15 Nos. 150 * 300 28 days Split cylinder
test
Disc 3 Nos. 15 Nos. 50 * 150 28 days Durability test
Total 33 Nos. 165 Nos

37
6.10 DETAILS OF TEST SPECIMENS

S. Name of Test Size of Min. No of Total

No specimen specimen
(3,7,28 day)
(mm) (Batch 11)

1 Compressive 150x150x150 11x9 = 99 297

strength

2 Split tensile strength 150x300 11x9 = 99

3 Flexural strength test 500x100x100 11x9 = 99

38
 CONCLUSION
From above research work we can found that ECA is soft aggregate which is
more use full in light weight concrete work. ECA is artificial lightweight aggregate. So in
this research work we are partially replace ECA with natural fine aggregate up to 40% and
hence there is the compressive strength of it found higher than normal concrete.
As per the research paper ECA has high water absorbing capacity so that there
is problem of absorbing moisture in fresh concrete. To overcome these problems immerse
ECA for 48 h before mixing and it provides internal curing to concrete which ultimately
increase its bond strength. Due to rounded shape and saturated aggregate is used workability
of concrete is increase as percentage of ECA increase.

39
 REFERENCES

 Concrete Technology Theory and Practice, M. S. Shetty, (S. Chand)

 Manual: Hand Book of Material Testing – IRICE
 Concrete Technology Book
 Research Paper :-

 study of reinforcement corrosion in expanded clay concrete(A.V. Uglyanitsa, N.V.

Gilyazidinova, A.A. Zhikharev, A.A. Kargin)
 comparison of material properties of lightweight concrete with recycled
polyethylene and expanded clay aggregates (deividas rumšysa*, darius bačinskasa,
edmundas spudulisa,b, adas meškėnasa,c)
 experimental investigation on mechanical properties of light weight concrete using
leca( T. SONIA1, R. SUBASHINI1)
 a comparison of strength and elastic properties between conventional and lightweight
structural concretes designed with expanded clay aggregates( murat emre dilli, hakan
nuri atahan , cengiz s_engül)
Many other Research paper studied for References.

 Internet website data using (Searching for Journal & Research Related)
 www.asce.lib
 www.ascelibrary.org
 www.sciencedirect.com
 IS CODE 10262 (2009) : Guideline for concrete mix design proportioning
 IS CODE 456 (2000) : Plain and Reinforced Concrete

40